Internally damped airfoiled component and method

ABSTRACT

An airfoiled component comprises: a root section, an airfoil section, a damper pocket enclosed within a portion of the airfoil section, and a damper. The airfoil section includes a suction sidewall and a pressure sidewall each extending chordwise between a leading edge and a trailing edge, and extending spanwise between the root section and an airfoil tip. The damper includes a fixed end unified with a damper mounting surface, and a free end extending into the damper pocket from the damper mounting surface.

BACKGROUND

The described subject matter relates generally to gas turbine airfoils,and more specifically to internally damped gas turbine airfoils.

External and internal dampers have been added to rotor blades to reduceor alter vibrational modes. Some internal dampers currently require thatthe two (suction and pressure) sides of the airfoil be formed separatelyand bonded together around the damper. In such cases, the internaldamper is not bonded to any of the internal blade walls or ribs Otherinternal dampers are inserted from the exterior of the blade andtherefore must be adapted so as not to interfere with the airfoilsurface.

SUMMARY

An airfoiled component comprises: a root section, an airfoil section, adamper pocket enclosed within a portion of the airfoil section, and adamper. The airfoil section includes a suction sidewall and a pressuresidewall each extending chordwise between a leading edge and a trailingedge, and extending spanwise between the root section and an airfoiltip. The damper includes a fixed end unified with a damper mountingsurface, and a free end extending into the damper pocket from the dampermounting surface.

A method of making an airfoiled component for a turbine engine comprisesproviding a first plurality of metal powder particles. An energy beam isselectively directed over the first plurality of metal powder particlesto form a first molten powder pool. At least a portion of the firstmolten powder pool is solidified to form a component wall build layer ona first deposition surface. A second plurality of metal powder particlesis provided. An energy beam is directed selectively over the secondplurality of metal powder particles to form a second molten powder pool.At least a portion of the second molten powder pool to form a damperbuild layer on a second deposition surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts an example turbofan engine.

FIG. 2A shows an internally damped airfoiled component for the exampleturbofan engine.

FIG. 2B is a cutaway view showing the airfoiled component with aninternal damper.

FIG. 3A is a first sectional view taken through the airfoiled component.

FIG. 3B is a second sectional view taken through the airfoiledcomponent.

FIG. 4 shows the airfoiled component formed by an additive manufacturingapparatus.

FIG. 5 is a chart listing steps of a method for forming an airfoiledcomponent.

DETAILED DESCRIPTION

FIG. 1 is a representative illustration of a gas turbine engine 10including a liner/vane assembly of the present invention. The view inFIG. 1 is a longitudinal sectional view along an engine center line.FIG. 1 shows gas turbine engine 10 including fan blade 12, compressor14, combustor 16, turbine 18, high-pressure rotor 20, low-pressure rotor22, and engine casing 24. Compressor 14 and turbine 18 include rotorstages 26 and stator stages 28.

As illustrated in FIG. 1, fan blade 12 extends from engine center lineCL near a forward end of gas turbine engine 10. Compressor 14 isdisposed aft of fan blade 12 along engine center line CL, followed bycombustor 16. Turbine 18 is located adjacent combustor 16, oppositecompressor 14. High-pressure rotor 20 and low-pressure rotor 22 aremounted for rotation about engine center line CL. High-pressure rotor 20connects a high-pressure section of turbine 18 to compressor 14.Low-pressure rotor 22 connects a low-pressure section of turbine 18 tofan blade 12 and a high-pressure section of compressor 14. Rotor stages26 and stator stages 28 are arranged throughout compressor 14 andturbine 18 in alternating rows. Thus, rotor stages 26 connect tohigh-pressure rotor 20 and low-pressure rotor 22. Engine casing 24surrounds turbine engine 10 providing structural support for compressor14, combustor 16, and turbine 18, as well as containment for air flowthrough engine 10.

In operation, air flow F enters compressor 14 after passing between fanblades 12. Air flow F is compressed by the rotation of compressor 14driven by high-pressure turbine 18. The compressed air from compressor14 is divided, with a portion going to combustor 16, a portion bypassesthrough fan 12, and a portion employed for cooling components,buffering, and other purposes. Compressed air and fuel are mixed andignited in combustor 16 to produce high-temperature, high-pressurecombustion gases Fp. Combustion gases Fp exit combustor 16 into turbinesection 18.

Stator stages 28 properly align the flow of air flow F and combustiongases Fp for an efficient attack angle on subsequent rotor stages 26.The flow of combustion gases Fp past rotor stages 26 drives rotation ofboth low-pressure rotor 20 and high-pressure rotor 22. High-pressurerotor 20 drives a high-pressure portion of compressor 14, as notedabove, and low-pressure rotor 22 drives fan blades 12 directly orthrough a gear reduction device (not shown) to produce thrust Fs fromgas turbine engine 10.

FIG. 2A shows airfoiled component 40 for turbine engine 10. FIG. 2A alsoincludes root section 42, airfoil section 44, suction sidewall 46,pressure sidewall 48, leading edge 50, trailing edge 52, airfoil tip 54,and platform 56.

Airfoiled component 40 is described as a vane or rotor blade suitablefor use in gas turbine engine 10 shown in FIG. 1. However, variousembodiments of airfoiled component 40 can additionally and/oralternatively be configured for installation into one or more locationsin example gas turbine engine 10, including fan blades 12, compressor14, and/or turbine 18. Airfoiled component 40 is also suitable for useas a blade or vane in other embodiments of gas and steam turbineengines.

In the example embodiment of FIG. 2A, airfoiled component 40 is shown asa cantilevered vane which includes root section 42 joined to airfoilsection 44. Airfoil section 44 can include suction sidewall 46 andpressure sidewall 48 each extending chordwise between leading edge 50and trailing edge 52. Suction sidewall 46 and pressure sidewall 48 eachextend spanwise between root section 42, and airfoil tip 54. Airfoiledcomponent 40 also includes platform 56 proximate the intersection ofroot section 42 and airfoil section 44. Root section 42 can optionallyinclude one or more coolant inlet passages (not shown).

As a cantilevered vane, airfoiled component 40 has a standard airfoiltip 54 adapted to contact and form a seal with a rotating element suchas a turbine rotor. However, depending on properties of airfoiledcomponent 40, airfoil tip 54 can alternatively include one or moreattachment and flow conditioning features such as a second platformand/or root. Other embodiments of airfoiled component 40 includeshrouded or unshrouded rotor blades with suitable features in place ofroot section 42 and/or airfoil tip 54. Unshrouded blades can have tipfeatures such as a tip shelf, tip recess, and/or squealer rib (notshown).

FIG. 2B shows airfoiled component 40 with a portion of pressure sidewall48 and platform 56 cut away to show damper pocket 58 and damper 62. FIG.2B also includes root section 42, airfoil section 44, suction sidewall46, leading edge 50, trailing edge 52, airfoil tip 54, damper pocket 58,damper 62, damper fixed end 64, damper free end 66, and damper mountingsurface 68.

Damper 62 extends spanwise along damper pocket 58, disposed on aninterior portion of airfoil section 44. Damper 62 can include fixed end64 metallurgically bonded to a surface of damper pocket 58. Damper freeend 66, extending generally toward airfoil tip 54, is able to movewithin damper cavity 58 and contact one or more damper cavity surfaces,thereby dissipating vibratory energy by friction and reducing thelikelihood of large vibratory response in different operational modes.Vibration can be caused at least in part by working gas flow(s) F, Fp,and/or Fs (shown in FIG. 1) flowing over airfoil section 44. Thus atleast airfoil section 44 and damper 62 can have a unitary constructionwhere both are fabricated using an additive manufacturing process, suchas a powder bed deposition process. Using this process, damper fixed end64 can be metallurgically bonded or unified with damper mounting surface68 in damper pocket 58.

FIGS. 3A and 3B are sectional views of airfoiled component 40. FIG. 3A,taken across section line 3A-3A of FIG. 2A, shows a side view ofairfoiled component 40 with damper pocket 58 and damper 62. FIG. 3B istaken across section line 3B-3B of FIG. 2A through airfoil section 44and damper free end 66. FIGS. 3A and 3B also include root section 42,suction sidewall 46, pressure sidewall 48, airfoil tip 54, damper fixedend 64, damper mounting surface 68, curved damper portions 70A, 70B,suction side damper pocket surface 72, pressure side damper pocketsurface 74, cooling cavity 75, rib 76, and temporary damper connection79.

In the example of FIGS. 3A and 3B, damper pocket 58 and damper 62 canextend generally spanwise along airfoil section 44 to facilitate dampingof airfoiled component 40. Additive manufacturing and unification ofboth damper 62 with a mounting surface of damper pocket 58 allows greatflexibility in the formation, efficacy, and useful life of internaldamped structures. Damper 62 can be configured in different ways tooptimize damping for a particular set of operating conditions. Duringoperation there is differential deflection of damper free end 66relative to one or both airfoil sidewalls (i.e., suction sidewall 46and/or pressure sidewall 48). In certain embodiments, such as statorvanes, relative deflection can occur due to airflow over airfoilsidewalls 46, 48 causing rotation or torquing of airfoil section 44relative to root section 42. Since damper fixed end 64 can bemetallurgically bonded to damper mounting surface 68 in damper pocket58, the result is that at least one portion of damper free end 66 restsagainst corresponding damper pocket surfaces spaced apart from dampermounting surface 68. In the example vane of FIG. 3A, first curved damperportion 70A contacts a first, or suction side damper pocket surface 72,while second curved damper portion 70B contacts a second, or pressureside damper pocket surface 74. These and other damper arrangements havethe effect of locally or globally changing vibrational modes of airfoilsection 44, and in turn, vibrational modes of airfoiled component 40.

In an alternative example where airfoiled component 40 is configured asa rotor blade, deflection of airfoil sidewalls 46, 48 relative to dampercan also occur due to rotation of airfoiled component 40 about enginecenter line CL (shown in FIG. 1). During rotation of component 40, thecentrifugal forces on airfoil portion 44 and damper 62 cause free end 66to trail fixed end 64. Simultaneously, centrifugal forces on free end 66cause damper 62 to straighten, so that in use, at least one portion offree end 66 rests against one or more surfaces generally at the outerend of damper pocket 58.

In certain embodiments, airfoiled component 40 also includes trailingedge cooling cavity 75. FIG. 3B shows rib 76 separating cavity 75 fromdamper pocket 58. In certain of these embodiments cavity 75 is in fluidcommunication with damper pocket 58. Additionally or alternatively,damper pocket 58 can itself operate as a cooling cavity. In doing so,root section 42 and/or airfoil section 44 can include one or morecoolant inlets and outlets (not shown).

At the time of additive manufacture or repair of airfoiled component 40,one or more portions of damper 62 can be temporarily secured to asurface of damper pocket 58. In FIG. 3B, first curved portion 70A ofdamper free end 66 is temporarily secured via a lightly sintered damperconnection 79 to pressure side damper pocket surface 74. Damperconnection 79 can be a localized, relatively weak metal structure suchas spaced apart mini-ribs or honeycombs. This can be done duringformation or repair of airfoiled component 40 by additive manufacturing(illustrative example shown in FIG. 4). By temporarily securing orsintering one or more portions of damper free end 66 during an additivemanufacturing process, damper 62 can remain secure during transportand/or installation of unitary airfoiled component 40.

Prior to or after installation of component 40 into a stator case,engine rotor, or other assembly (not shown), airfoil section 46 can bemanipulated, heated, vibrated, or otherwise treated to break aparttemporary damper connection 79, which separates free end 66 from thecorresponding surface(s) of damper pocket 58. If airfoiled component 40is configured as a rotor blade, the rotor can be operated in a break-inmode to break apart the one or more temporary damper connections 79.Operating of the rotor can be done either by balancing the rotor outsideof the engine, or through a balancing sequence occurring afterinstallation of the rotor into the engine. It will be appreciated thatin certain embodiments, damper free end 62 can include multipletemporary damper connections localized in different areas of dampercavity 58 so as to help create and maintain more complex damper andcavity geometries during manufacture and/or repair of unitary airfoiledcomponent 40.

In other examples, materials of construction for airfoiled component 40can be easily optimized using additive manufacturing processes andapparatus. In one example, airfoil section 44 can include at least oneairfoil alloy composition, and damper 62 can include at least one damperalloy composition. In certain embodiments, at least one of the airfoilcompositions can be substantially identical to the at least one damperalloy composition. This allows certain portions of both airfoil section44 and damper 62 to be formed simultaneously in a layerwise manner,using a standard powder bed or other additive manufacturing apparatus.

Alternatively, the airfoil alloy composition(s) can be tailored towithstand high thermal and mechanical loads in the flowpath, while thealloy composition(s) of internal damper 62 are different from the damperalloy composition(s) to favor the mechanical properties of the damperover its thermal resistance. This can occur, for example, when damperpocket 58 forms at least a portion of a cooling cavity or other airfoilpassage. Additive manufacturing also allows and simplifies theintegration of a damper pocket and an airfoil cooling passage withreduced cooling losses due to a more secure internal connection of thedamper, rather than using a damper which is insertable from the outsideof the component.

In another example, the geometry of damper(s) 62 can be more carefullytailored to particular vibrational modes in different regions of theairfoil. For example, damper fixed end 64 can have larger thicknessand/or chordwise dimensions as well as a stronger alloy composition tomaintain secure bonding around the base of damper pocket 58. Toward freeend 66, damper 62 can have dimensions, curvature, and alloy compositionstailored to the vibrational characteristics of airfoil section 46disposed in the engine flowpath. Forming the damper via conventionaltechniques such as forging or powder metallurgy reduces the ability todesign more flexible damper geometries and tailor alloy compositions formore complex airfoil designs which are also made possible via additivemanufacturing.

FIGS. 3A and 3B show a single damper 62 and damper pocket 58. However,in certain embodiments, it will be appreciated that a plurality ofdampers 62 can extend spanwise along damper pocket 58. In this case,each damper 62 can include fixed end 64 metallurgically bonded orunified with a surface of the damper pocket 58, with free ends 66contacting other surfaces of pocket 58 in use of component 40. Asubstantial portion of each damper 62 can be built in a layerwise mannerand unified with a damper mounting surface via an additive manufacturingprocess. Additionally or alternatively, airfoil section 44 can includemultiple damper pockets 58 each with one or more dampers 62 unified tocorresponding damper pocket mounting surface(s). In these and otherembodiments, airfoil section 44, damper pocket(s) 58 and damper(s) 62can have a unitary construction and a substantial portion of each can befabricated using an additive manufacturing process. In certainembodiments with one or more dampers 62, damper pocket(s) 58 can bedefined by surfaces including one or more of: suction sidewall 46,pressure sidewall 48, and internal rib(s) 75.

FIG. 4 illustrates the making of a airfoiled component using an exampleadditive manufacturing apparatus 110. Embodiments of apparatus 110utilize various additive manufacturing processes such as but not limitedto direct laser sintering (DLS) manufacturing, direct laser melting(DLM) manufacturing, selective laser sintering (SLS) manufacturing,selective laser melting (SLM) manufacturing, laser engineering netshaping (LENS) manufacturing, electron beam melting (EBM) manufacturing,direct metal deposition (DMD) manufacturing, and others known in theart.

Build table 114 includes movable build platform 116, which can be anyobject which is capable of being mounted to additive manufacturingapparatus 110 for building one or more near-net shape components. Powderdelivery system 118 is capable of supplying successive quantities ofmetal powder to build platform 116. In this example, powder deliverysystem 118 includes powder compartment 120 with powder elevator platform122 disposed proximate to, and movable opposite build platform 116.Build arrows 124 indicate that powder elevator platform 122 is movablein a first vertical direction, and build platform 116 is movable in asecond vertical direction opposite the first vertical direction.However, it will be appreciated that other powder supply arrangementscan be used such as those where the metal powder is injected into anenergy beam before it reaches the intended deposition surface(s). Thisnon-limiting example of energy beam apparatus 126 shows beam generator128 and outlet lens 130 adapted to steer energy beam 132 generally alongbeam path 134 toward build platform 116. This example is simplified forbrevity, and it will therefore be understood that other more complexelectron or laser beam configurations (e.g., steering mirrors, prisms,and/or multi-axis CNC systems) can be incorporated to operate otherembodiments of energy beam apparatus 126.

FIG. 4 also shows powder bed build plate 136 disposed on build platform116 to serve as a substantial portion of an initial working surface forbuild assembly 140. A plurality of successively deposited powder buildlayers are provided from powder supply 142 by recoater 144 to buildassembly 140. Each powder build layer converted into successively formedcomponent build layers according to a computer model, which can bestored in an STL memory file or other electronic data file accessible bya controller (not shown) of additive manufacturing apparatus 110.Selective areas of each successive deposited layer can be sintered orotherwise adhered to the preceding layer by energy beam 132. After eachsuccessive layer, recoater 144 is returned to a starting position nearelevator platform 122, while supply piston 146 advances upward to exposeanother layer from powder supply 142, while build platform 116 indexesdown by approximately one layer thickness. The process is repeated untilbuild assembly 140 is complete with one or more near-net shape airfoiledcomponents 40 built in a layerwise manner. FIG. 4 shows only onenon-limiting example of a powder bed type additive manufacturing processand apparatus, and is not meant to limit the described subject matter toa single process or machine.

In FIG. 4, component base 80 is removably secured to build plate 136. Inone example, base 80 can be a precursor to a component root section(e.g., root section 42) of a rotor blade, stator vane, or otherairfoiled component. In certain embodiments, base 80 is formed forexample via a combination of forging, casting, machining, or otherconventional metallurgical processes. Alternatively, base 80 can bestarted from scratch and built in a layerwise fashion by additivemanufacturing apparatus 110 before being used as the foundation for therest of the component (e.g., airfoil section 44 and damper 62). In yetother alternative embodiments, airfoil section 44 and damper 62 arebuilt first on a sacrificial surface by additive manufacturing apparatus110, and subsequently, base 80 can be metallurgically bonded tocompleted airfoil section 44.

In FIG. 4, both airfoil walls 46, 48 and damper(s) 62 can be built up ina layerwise fashion. Portions of airfoil section 44 are omitted tobetter show damper pocket 58 and damper 62. Each component wall buildlayer can be formed by providing a first quantity of metal powder to afirst deposition surface. At least a portion of this first quantity ofmetal powder can then be selectively melted into a molten pool (notshown), for example, by selectively steering energy beam 132 thereover.At least a portion of the first molten pool can then be solidified intoa subsequent component wall build layer 150A adhered to a precedingcomponent wall build layer, or other structure serving as a firstdeposition surface. Iteratively performing these steps result information of one or more substantially complete component or airfoilsidewalls comprising a plurality of successive component wall buildlayers.

Along with formation of each component wall build layer, each damperbuild layer can be formed by providing a second quantity of metal powderto a second deposition surface. The second deposition surface may bedisposed inward of the first deposition surface. Energy beam 132 can beselectively scanned over the second plurality of dispensed metal powderparticles to form a second molten powder pool (not shown). At least aportion of the second molten pool can then be solidified into asubsequent damper wall build layer 150B adhered to a preceding damperwall build layer or other structure serving as the second depositionsurface. Iteratively performing these steps result in formation of oneor more substantially complete dampers unified with a damper pocketmounting surface. The damper(s) can include a plurality of successivedamper build layers.

Generally, each successive iteration of the first and second depositionsurface(s) comprise at least a portion of a preceding build layer 150A,150B. There may be some overhang and discontinuities, depending on thefinal build requirements and the capabilities of the build apparatus.

The first and second deposition surfaces can also be contiguous portionsof the same surface, for example when forming the initial build layerson base deposition surface 82, and/or when forming a temporary damperconnection between damper free end 66 and damper pocket 58 (see, e.g.,damper connection 79 in FIG. 3B). The initial damper wall build layercan thus be adhered to and unified with the second portion of basedeposition surface 82. In certain embodiments, damper pocket 58 mayextend into base 80.

Additive manufacturing of both airfoil portion 44 and damper 62 allowsunification of damper 62 and a mounting surface of damper pocket 58.This makes the connection of damper 62 more secure and robust, whichreduces the need to repair or replace damper 62 before the end of theuseful life of component 40. Additive manufacturing also allows forcontrolled deposition of one or more alloy transitional regions toaccommodate varying alloy compositions used throughout airfoiledcomponent 40.

In certain embodiments, build layers are stacked generally in a spanwisedirection. However, it will be appreciated that in certain embodimentssuch as those with an internal cooling configuration and/or multipledamper cavities, the surfaces of damper cavity 58 can comprise one ormore of: a suction sidewall, a pressure sidewall, and an internal rib.

In certain embodiments, both first and second powder layers can beprovided to the respective deposition surfaces before solidifying eitherof them into a build layer. Alternatively, some or all of the damper canbe built up in a layerwise fashion prior to the component walls (e.g.,airfoil sidewalls and/or optional ribs) being built up therearound.Similarly, the component walls can be built first with the damper(s) tofollow. This may be done with multiple, relatively small damper pocketswhere it is relatively easy to remove excess powder prior to enclosingeach damper pocket. With larger dampers, a LPD or LENS type machine orsimilar machine can be used in which the powder is injected directlyinto the energy beam, rather than being supplied using a powder bed typesystem.

FIG. 5 summarizes example steps of forming a airfoiled component. Steps202 to 206 relate to layerwise forming of a component wall such asairfoil sidewalls 46, 48 (shown in FIG. 4). Steps 208 to 212 relate toforming a damper such as damper 62 (also shown in FIG. 4).

In step 202, shown in FIG. 5, a first plurality of metal powderparticles are provided. Step 204 includes directing an energy beamselectively over the first plurality of metal powder particles to form afirst molten powder pool. This can be done, for example, using a powderbed deposition apparatus wherein the first plurality of metal powderparticles are provided to a surface prior to directing the energy beam.Alternatively, the metal powder particles are directly injected into thebeam to form the molten pool. At step 206, at least a portion of thefirst molten powder pool is solidified to form a component wall buildlayer on a first deposition surface such as a preceding component wallbuild layer 152 or base deposition surface 82 (shown in FIG. 4).

Step 208 includes providing a second plurality of metal powderparticles. At step 210, an energy beam is selectively directed over thesecond plurality of metal powder particles to form a second moltenpowder pool. Similar to the formation of the first molten pool in steps202 and 204, this can be done with either a powder bed depositionapparatus or by injecting the powder directly into an energy beam. Instep 212 at least a portion of the second molten powder pool can besolidified to form a damper build layer on a second deposition surface.

Various steps of method 200 can be iteratively performed to make aplurality of airfoiled components such as those shown and described withrespect to FIGS. 1-4. After these steps each damper can then be enclosedwithin a damper pocket. In certain embodiments, enclosing the damperincludes layerwise forming a tip or other portion of the airfoil onto asubstantially contiguous layer of the airfoil wall. To preventcomplications due to excessive overhang, the walls may be tapered orangled in such a way that each layer of powder and the resulting poolcan adhere to the previous deposition surface until solidification.Alternatively, a separately formed tip portion (e.g., casting, forging,and/or machining) can be metallurgically bonded to a final substantiallycontiguous layer of the article/airfoil wall.

Discussion of Possible Embodiments The following are non-exclusivedescriptions of possible embodiments of the present invention:

An airfoiled component comprises: a root section, an airfoil section, adamper pocket enclosed within a portion of the airfoil section, and adamper. The airfoil section includes a suction sidewall and a pressuresidewall each extending chordwise between a leading edge and a trailingedge, and extending spanwise between the root section and an airfoiltip. The damper includes a fixed end unified with a damper mountingsurface, and a free end extending into the damper pocket from the dampermounting surface.

The apparatus of the preceding paragraph can optionally include,additionally and/or alternatively, any one or more of the followingfeatures, configurations and/or additional components:

A further embodiment of the foregoing airfoiled component, wherein thefixed end of the damper is unified with the damper mounting surfaceusing an additive manufacturing process.

A further embodiment of any of the foregoing airfoiled components,wherein the airfoil section comprises a plurality of stacked componentwall build layers forming the suction sidewall and the pressuresidewall.

A further embodiment of any of the foregoing airfoiled components,wherein the damper comprises a plurality of stacked damper build layersforming the fixed end and the free end.

A further embodiment of any of the foregoing airfoiled components,wherein the airfoil section includes a first airfoil alloy composition,and the damper includes a first damper alloy composition.

A further embodiment of any of the foregoing airfoiled components,wherein the first airfoil alloy composition is substantially differentfrom the first damper alloy composition.

A further embodiment of any of the foregoing airfoiled components,wherein the damper also includes a second damper alloy compositionhaving a strength greater than a strength of the first damper alloycomposition.

A further embodiment of any of the foregoing airfoiled components,wherein the fixed end of the damper is formed using the second damperalloy composition, and the free end of the damper is formed using thefirst damper alloy composition.

A further embodiment of any of the foregoing airfoiled components,wherein the damper pocket comprises a portion of an airfoil coolingcavity.

A further embodiment of any of the foregoing airfoiled components,further comprising: a temporary damper connection between the free endof the damper and a damper pocket surface.

A further embodiment of any of the foregoing airfoiled components,further comprising a plurality of dampers, each damper including a fixedend unified with a corresponding damper mounting surface, and a free endextending into the damper pocket from the damper mounting surface.

A further embodiment of any of the foregoing airfoiled components,further comprising a plurality of damper pockets enclosed within aportion of the airfoil section, each of the damper pockets including adamper mounting surface.

A method of making an airfoiled component for a turbine engine comprises(a) providing a first plurality of metal powder particles. (b) An energybeam is selectively directed over the first plurality of metal powderparticles to form a first molten powder pool. (c) At least a portion ofthe first molten powder pool is solidified to form a component wallbuild layer on a first deposition surface. (d) A second plurality ofmetal powder particles is provided. (e) An energy beam is directedselectively over the second plurality of metal powder particles to forma second molten powder pool. (f) At least a portion of the second moltenpowder pool to form a damper build layer on a second deposition surface.

The method of the preceding paragraph can optionally include,additionally and/or alternatively, any one or more of the followingsteps, features, configurations and/or additional components:

A further embodiment of the foregoing method, wherein a first iterationof step (a) and a first iteration of step (d) are both performed priorto a first iteration of any of steps (b), (c), (e) and (f).

A further embodiment of any of the foregoing methods, wherein a firstiteration of steps (b), (c), (e) and (f) are each performed subsequentto either a second iteration of step (a) or a second iteration of step(d).

A further embodiment of any of the foregoing methods, wherein a firstiteration of steps (a)-(c) and a second iteration of steps (a)-(c) areperformed prior to a first iteration of steps (d)-(f).

A further embodiment of any of the foregoing methods, further comprisingiteratively performing steps (a)-(c) to form an airfoil sectioncomprising a plurality of successive component wall build layers, eachof the plurality of successive component wall build layers formed on acorresponding plurality of successive first deposition surfaces.

A further embodiment of any of the foregoing methods, wherein eachsuccessive first deposition surface comprises at least a portion of apreceding component wall build layer.

A further embodiment of any of the foregoing methods, wherein theairfoil section includes at least one component wall bounding a damperpocket, the damper pocket having a damper mounting surface.

A further embodiment of any of the foregoing methods, furthercomprising: iteratively performing steps (d)-(f) to form at least onedamper unified with the damper mounting surface, the damper comprising aplurality of successive damper build layers; wherein each of theplurality of successive damper build layers is formed on a correspondingplurality of successive second deposition surfaces.

A further embodiment of any of the foregoing methods, wherein eachsuccessive first deposition surface comprises at least a portion of apreceding component wall build layer.

A further embodiment of any of the foregoing methods, further comprisingforming a temporary damper connection between a free end of the at leastone damper and a damper pocket surface spaced apart from the dampermounting surface.

A further embodiment of any of the foregoing methods, further comprisingenclosing the at least one damper within the damper pocket.

A further embodiment of any of the foregoing methods, wherein theenclosing step comprises layerwise forming a tip portion of the airfoilsection.

A further embodiment of any of the foregoing methods, wherein theenclosing step comprises metallurgically bonding a separately formed tipportion to the airfoil section.

A further embodiment of any of the foregoing methods, wherein the damperpocket is bounded by: a suction sidewall, a pressure sidewall, and/or aninternal rib.

A further embodiment of any of the foregoing methods, wherein the damperpocket comprises at least a portion of an airfoil cooling passage.

A further embodiment of any of the foregoing methods, wherein the firstmetal powder comprises a first airfoil alloy composition, and the secondmetal powder comprises a first damper alloy composition.

A further embodiment of any of the foregoing methods, wherein the firstairfoil alloy composition is substantially different from the firstdamper alloy composition.

A further embodiment of any of the foregoing methods, wherein steps(a)-(f) are performed using an additive apparatus apparatus selectedfrom a group consisting of: a direct laser sintering (DLS) apparatus, adirect laser melting (DLM) apparatus, a selective laser sintering (SLS)apparatus, a selective laser melting (SLM) apparatus, a laserengineering net shaping (LENS) apparatus, an electron beam melting (EBM)apparatus, and a direct metal deposition (DMD) apparatus.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

The invention claimed is:
 1. A method of making an airfoiled componentfor a turbine engine, the method comprising: (a) providing a firstplurality of metal powder particles; (b) directing an energy beamselectively over the first plurality of metal powder particles to form afirst molten powder pool; (c) solidifying at least a portion of thefirst molten powder pool to form a component wall build layer on a firstdeposition surface; (d) providing a second plurality of metal powderparticles; (e) directing an energy beam selectively over the secondplurality of metal powder particles to form a second molten powder pool;(f) solidifying at least a portion of the second molten powder pool toform a damper build layer on a second deposition surface; iterativelyperforming steps (a)-(c) to form an airfoil section comprising aplurality of successive component wall build layers, each of theplurality of successive component wall build layers formed on acorresponding plurality of successive first deposition surfaces, whereinthe airfoil section includes at least one component wall bounding adamper pocket, the damper pocket having a damper mounting surface;forming a temporary damper connection between a free end of at least onedamper and a damper pocket surface spaced apart from the damper mountingsurface, wherein the temporary damper connection comprises honeycombs;iteratively performing steps (d)-(f) to form the at least one damperunified with the damper mounting surface, the at least one dampercomprising a plurality of successive damper build layers; wherein eachof the plurality of successive damper build layers is formed on acorresponding plurality of successive second deposition surfaces; andbreaking apart the temporary damper connection via the application of atleast one of heating and vibrating.
 2. The method of claim 1, wherein afirst iteration of step (a) and a first iteration of step (d) are bothperformed prior to a first iteration of any of steps (b), (c), (e) and(f).
 3. The method of claim 2, wherein a first iteration of steps (b),(c), (e) and (f) are each performed subsequent to either a seconditeration of step (a) or a second iteration of step (d).
 4. The methodof claim 1, wherein a first iteration of steps (a)-(c) and a seconditeration of steps (a)-(c) are performed prior to a first iteration ofsteps (d)-(f).
 5. The method of claim 1, further comprising: enclosingthe at least one damper within the damper pocket.
 6. The method of claim5, wherein the enclosing step comprises: layerwise forming a tip portionof the airfoil section.
 7. The method of claim 5, wherein the enclosingstep comprises: metallurgically bonding a separately formed tip portionto the airfoil section.
 8. The method of claim 1, wherein the damperpocket is bounded by one or more of: a suction sidewall, a pressuresidewall, and an internal rib.
 9. The method of claim 1, wherein thedamper pocket comprises at least a portion of an airfoil coolingpassage.
 10. The method of claim 1, wherein the first metal powdercomprises a first airfoil alloy composition, and the second metal powdercomprises a first damper alloy composition.
 11. The method of claim 10,wherein the first airfoil alloy composition is substantially differentfrom the first damper alloy composition.
 12. The method of claim 1,wherein steps (a)-(f) are performed using an additive manufacturingapparatus selected from a group consisting of: a direct laser sintering(DLS) apparatus, a direct laser melting (DLM) apparatus, a selectivelaser sintering (SLS) apparatus, a selective laser melting (SLM)apparatus, a laser engineering net shaping (LENS) apparatus, an electronbeam melting (EBM) apparatus, and a direct metal deposition (DMD)apparatus.
 13. The method of claim 1, wherein breaking apart thetemporary damper connection comprises operating the airfoiled componentin a break-in mode to break apart the temporary damper connection.